Method for thermal relay welding

ABSTRACT

Members are welded together by indirect application of heat, as for welding internal battery posts for connecting groups of plates or terminal posts electrically, through the use of a plurality of heated elements simultaneously engaging posts to be welded together, and wherein the configuration of molten material is controlled as the weld cools, by the use of a templet. The elements are heated, preferably by application of open flame through a plurality of mixing systems for the fuel, with one system being provided for each heated element.

REFERENCE TO RELATED APPLICATIONS

This is a division of application Ser. No. 432,545, filed Jan. 11, 1974,now U.S. Pat. No. 3,954,216, which is a continuation-in-part of U.S.patent application Ser. No. 395,528 filed Sept. 10, 1973 now U.S. Pat.No. 3,861,575, dated Jan. 21, 1976, which in turn is a divisionalapplication of U.S. application Ser. No. 184,338 filed Sept. 28, 1971now abandoned.

BACKGROUND OF THE INVENTION

This invention relates to welding in general, and specifically forwelding posts of batteries, as for example of the type used inautomobiles.

In the welding of various members together, it is commonplace to use awelding rod having a flux therein, for many types of welding, such asarc welding. In other instances, particularly when the materials beingwelded together are soft, such as those comprising pot metal, lead, leadalloys or like materials, welding may be effected by application of openflame to members that are to be welded together. In many instances suchtechniques are highly desired and quite meritorious.

However, in some instances, as for example when electrical conductivityis desired, it becomes paramount that the connection between membersbeing welded be such as to create minimal electrical resistance.

In the art of battery manufacture, particularly wet cell batteries forautomobile usage and the like, it has become commonplace to utilize wetcell batteries, having a plurality of cells. In each cell, there aredisposed a plurality of parallel but spaced plates, each having a lugextending therefrom, with the various lugs being interconnected by abattery strap, by any suitable means, such as that disclosed in U.S.Pat. No. 3,395,748. Extending from a strap of this type which connectsplates of a given cell, is a post. Adjacent cells of a given battery areseparated by cell partitions. Posts of groups of plates in adjacentcells must be connected, for electrical conductivity between cells.Accordingly, it is this connection of adjacent battery cell posts thatis of primary concern in this application.

Because of the presence of a cell partition between the posts, the postsare somewhat spaced at their upper ends, in that the posts extendgenerally upwardly above the height of the cell partitions, such upwardextension or protrusion facilitating the application of heat thereto,for obtaining an electrical connection between the posts across theupper end of an associated plate. Because of the necessity of obtaininggood electrical conductivity across such post connections, the art ofwelding battery posts has become highly developed, with individuals forperforming the same having developed a high degree of skill with respectthereto.

However, because such posts are generally spaced by the thickness of acell partition, the flame achieved by the use of a gas-oxygen torch orthe like must be raised to such a temperature that will permit thedelivery of a sufficiently high temperature at the lower end of thespacing between adjacent posts, if it is desired to adhere the poststogether as close as possible to the cell partition at the lower end ofthe spacing. However, in raising the welding temperature to such alevel, excessive temperatures are reached at the uppermost ends of theposts, most closely located relative to the torch which accomplishessuch "burning", such that early metal flow from the upper ends of theposts commences, such flow continuing down into the space between theposts, above the separator plate, and solidifying there, before lowerends of the posts in the vicinity of the upper end of the separatorplate have become sufficiently heated, thereby resulting in anincomplete fusion of metal at a location corresponding to the upper edgeof the cell partition. Thus, the result is that while a good fusion mayexist at the upper ends of posts thus welded, often, at the lowermostends of such posts, directly above the separator plate, the fusion isimperfect, with insufficient bond to provide sufficiently low electricalresistance as a connector. In order to avoid this, an operator may playthe torch between the posts, in order to assure a good weld in the lowerzone of such space above the separator plates or partitions, but suchmay cause the cell partitions to be scorched or damaged. Accordingly,the result is that present techniques of welding battery posts oftenresults in variations or lack of uniformity in weldments of batteries,depending upon the particular operator or welder involved, as well asresulting in an undesirable percentage of rejects due to welds that havea sufficiently good external appearance to pass customary qualitycontrol, but which are really poor weldments. Furthermore, batterieshaving poor weldments of battery posts are more prone to cause operatingdifficulties.

SUMMARY OF THE INVENTION

The present invention is directed toward overcoming the above and otherdifficulties in connection with the welding of battery posts, as well aswith welding in general by providing a novel method and apparatuswhereby adjacent members, such as battery posts, and terminal posts maybe indirectly welded by the use of a solid heat sink which penetratesthe members to be welded, as it liquifies the same, thereby carrying thetemperature of welding through the zone to be welded, in order toachieve uniformity in welds, as well as for other purposes.

Accordingly, it is a primary object of this invention to provide a novelmethod for welding together members that are to be welded, preferably byindirect application of heat thereto.

It is a further object of this invention to accomplish the above object,when the members are spaced apart, preferably in order to secure a goodweld across a cell partition located between, but below the upper endsof the members that are to be welded together over the separator.

It is a further object of this invention to provide a novel method andapparatus for welding together battery posts.

It is another object of this invention to provide a novel weldingmechanism, for delivering and mixing gases that are to be used inwelding, and for applying the same to heat sink carried thereby.

It is a further object of this invention to accomplish the above object,wherein locating plates are utilized, in order to properly position aplurality of welding elements on the apparatus, in accordance withpredetermined locations.

It is a further object of this invention to provide a novel method andapparatus for welding together battery posts, together with a means formolding the posts to desired configurations during solidificationthereof after the welding has been effected.

Further objects of this invention reside in the construction ofparticularly novel welding apparatus more fully described hereinafter.

Other objects and advantages of the present invention, such as apparatusand method particularly directed toward the welding of battery posts,will be readily apparent, as will be objects of a generally broadernature, from a reading of the following brief descriptions of thedrawing figures, detailed description of the preferred embodiment, andthe appended claims.

IN THE DRAWINGS

FIG. 1 is a side elevational view of an apparatus for welding batteryposts, in accordance with this invention disposed above a battery thatin itself is partially illustrated in section for clarity ofillustration, with the battery being disposed on a conveyor.

FIG. 2 is an enlarged fragmentary transverse view, of a portion of theapparatus illustrated in FIG. 1, taken generally along the line 2--2 ofFIG. 1.

FIG. 3 is a further enlarged fragmentary sectional view, taken throughone of the heat-applying devices of this invention, taken generallyalong the line 3--3 of FIG. 2.

FIG. 4 is a perspective view of some of the welding apparatusillustrated in FIG. 1.

FIG. 5a is a fragmentary view of a pair of upstanding battery posts witha cell partition between adjacent battery cells being disposedtherebetween.

FIG. 5b is a fragmentary view of the pair of adjacent battery posts ofFIG. 5a, with a templet disposed thereover, and with a welding elementreceived within the templet, at the lower end of its stroke ofpenetration of liquified post portions.

FIG. 5c is a fragmentary view of portions of the illustration of FIG.5b, at a later stage, after withdrawal of a welding element from thevoid in the templet in which the liquid mass will be molded into solidform.

FIG. 5d is a fragmentary transverse view of a completed weld of batteryposts of adjacent cells, welded across a partition, and with a batterycover being fragmentally illustrated in phantom disposed thereover, inorder to best illustrate the manner in which a cover may accurately fitover an accurate and uniform battery post welded in accordance with thisinvention.

FIG. 6 shows an assembled view of an alternate illustrative embodimentof the principles of the present invention which features flexiblyadjustable locations for the heating elements and also a flexibletemplet system.

FIG. 7 shows a cutaway of a portion of the FIG. 6 apparatus.

FIG. 8 shows in cutaway a variable position templet embodying theprinciples of the present invention.

FIG. 9 shows an overlaying plate to regulate the position of the heatingelements, as desired.

FIGS. 10a through 10d show the operation of the apparatus of FIGS. 6through 9 to secure terminal posts to bushings therefor.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in detail, reference is first made to FIG.1, and particularly to the lower end thereof, wherein there isillustrated a battery, generally designated by the numeral 10, disposedupon a conveyor 11, having a plurality of transverse rollers 12, formovement of the battery 10 from left to right, as viewed in FIG. 1,across the rollers 12.

A plurality of cells (six in number), such as those 13 and 14 areillustrated, in which are disposed a plurality of plates 15 extendingdownwardly from plate straps such as those 16 and 17, the plate straps16 and 17 having been already connected to the plate 15, by any suitablemeans, such as that described in U.S. Pat. No. 3,395,748, or by anyother means.

The cells 13 and 14 are separated by suitable cell partitions 18,constructed of an inert material, such as plastic or rubber (due to thepresence of battery acid within the cells 14, 15, etc.). The partition18 extends vertically upwardly between posts 20 and 21 of adjacent cells14 and 13, respectively, with the partition 18 terminating at its upperend short of the upper ends of the posts 20 and 21, leaving a space 22therebetween.

It is this space 22 that, upon welding by the use of open flame beingapplied to posts 20 and 21, may become filled with molten or liquid lead(or other post material) from the upper ends of the posts 20 and 21, andflow downwardly to solidify in the space 22 just above the separatorplate 18, without application of a proper amount of heat to thoseportions of the posts 20 and 21, below the upper ends thereof asillustrated in FIG. 5a, in the vicinity of the upper end of the cellpartition 18.

A templet 23, constructed of some material (preferably metal) having amelting point substantially in excess of that of the material of theposts 20 and 21, is provided, on the battery, at the upper ends thereof,as illustrated in FIG. 1, with pairs of posts 20 and 21 extendingupwardly through voids 24 therein. It will be clear that the voids 24extend entirely through the templet 23, and that the voids 24 comprisecentral portions 25 of a desired size and configuration corresponding tothe posts, to easily receive and contain the same.

The upper and lower ends of the voids 24 are countersunk as at 26 and27, to permit reception of posts 20 and 21 through the lower ends 27 ofthe voids 24, and to provide a dished portion 26 at the upper end ofeach void 24, to accommodate the reception of molten metal during thewelding operation, with the lower countersink or cut-away portion 27also facilitating the removal of the templet 23 after the weldingoperation is complete, with the weldments solidified. It will further benoted that the templet 23 is received on the upper lip of the casing 28of the battery 10, as illustrated in FIG. 1.

With particular reference to FIGS. 5a, and 5b and 5c, it will be seenthat a heated element 30 that has been heated by means later to bedescribed herein, to a temperature sufficient to melt the upper ends ofposts 20 and 21 of adjacent battery cells, across the top of a partition18, is lowered into engagement with the upper ends of the posts 20 and21, and proceeds to melt the same, into a liquid state, and thencontinue its downward move at, penetrating the liquid portions of thepost members 20 and 21 being progressively melted as the element 30moves downwardly, throughout a predetermined vertically downward strokeof movement of the element 30, such stroke also including a dwell timeat the lower end thereof, as illustrated in FIG. 5b, if desired (butsuch dwell not being required), followed by retraction, or verticallyupward movement of the element 30, in the direction of the arrow 31illustrated in FIG. 5c, whereby the mass of liquid melt displaced intothe zone 26 of the templet 23 during that portion of the operationillustrated in FIG. 5b, is free to fill the zone 25 of the void 24 ofthe templet 23, above the upper end of the partition 18, as illustratedin FIG. 5c, for cooling and solidification of the melt in the zone 25.It will be noted that a plurality (five in number) of such elements 30may be utilized simultaneously, in order to simultaneously effect fivedifferent welds, between posts of adjacent battery cells, or in fact anydesired number of such weldments may be effected, for battery cells, orfor any other purpose, by the above-mentioned method of maintaining aconstant temperature for the element 30 and delivering such temperaturecompletely throughout the zone of the posts 20 and 21, or other members,in which the weldment is desired.

Furthermore, it will be noted that the voids 24, and particularly thecentral portions 25 thereof, comprise molds for the welds, duringsolidification and cooling thereof. After the welds are solidified, thetemplet 23 may be removed from the casing 28 of the battery 10, forreuse, as desired.

With particular reference to FIG. 5d, it will be apparent that a batterycover 32, having an annular cylindrical protrusion 33, for each pair ofbattery posts welded together, may be disposed over the upper end of thebattery, with each weld 34 being received within a corresponding annularprotrusion 33, for purpose of aligning the battery cover 32, if desired,and for facilitating the covering of the welds 34 and retention of thecover 32 on the battery 10.

It will further be noted that the welds 34 are simultaneously effected,for a given battery, and are all uniform, as regards their electricalqualities, and as regards their general height and other physicalcharacteristics. Particularly as regards the height of the same, it willbe noted that, all being of the same general height, the battery cover32 will more easily fit thereover, with posts having welds 34 at theupper ends thereof, all being uniformly received in uniformly sizedannular protrusions 33 of the covers 32.

Referring now to the welding apparatus of this invention specificallyillustrated in FIGS. 1 through 4, it will be seen that an apparatus 40is presented, for carrying a plurality of heating elements or heat sinks30 protruding outwardly (downwardly) from the lower end thereof.

The apparatus 40 comprises a post 41 of cylindrical configuration,connected by any suitable means, such as threading or the like, as at42, through a manifold head 43, and through a base member 44, to besecured by means of a nut 45 therebeneath. The base member 44 is ofchannel-like construction, being generally of inverted U-shape intransverse cross-sectional configuration, as best illustrated in FIGS. 2and 4. The manifold head 43 is secured to the upper end of the base 44,by any suitable means, such as screws or the like. The manifold head 43is provided with a pair of conduits 46 and 47 extending longitudinallytherethrough, each connected at one end to an associated gasdistribution conduit 48 or 50, provided with associated on-off inletvalves 51, as desired. The conduits 48 and 50 are connected to suitablesources of gases, such as natural gas and oxygen, respectively, or anyother gases that will facilitate and support combustion at the desiredtemperatures. Thus, acetylene gas may replace the natural gas ifdesired, as may a mixture of other gases, such as air, replace theoxygen, if desired.

The left-most end of each of the manifold channels 46 and 47 is closed,as blind conduits (not illustrated).

Five element heating means, generally designated each by the numeral 42are provided, each of substantially identical construction, so that onlyone need be described in detail, and each of which is carried at thelower end of the base member 44, by a suitable horizontal plate 53,secured by means of a cap headed screw 54 or the like extendingtherethrough, in engagement within a nut 55 disposed within the base 44.Thus, the position of any given element heating means 52 may be alteredby loosening the screw 54, and repositioning such desired elementheating means by moving the plate 53 longitudinally of the base member44.

Each of the heating means 52 is constructed as an independent torch,being provided at its upper end with a mixing device 57, having upperinlets 58 and 60 for receiving for example gas and oxygen therein fromrespectively associated hoses 61 and 62 that, in turn are respectivelyconnected to associated manifold ducts 46 and 47, for supplying gas andoxygen to a chamber 63 disposed within the device 57, in which they aremixed.

Accordingly, the inlets 58 and 60 communicate respectively with thechamber 63. A pair of needle adjustments 64 and 65 are provided,associated with respective inlets 58 and 60, each comprising a thumbscrew or the like 66, operative through a boss 67 in threaded engagementwith the device 57 at 68, for adjusting the position of a needle 70 inthe associated inlet, for regulating the amount of gas to be mixed withoxygen, and the converse. Upon arriving at a desirable gas-oxygenmixture, the mixture passes through the conduit 71, to discharge fromthe device 57, through a distribution line 72, that in turn is connectedto an element holder 73, by suitable nuts 74 or the like in threadedengagement with threads 75, wherein the delivery line 76 is bifurcatedat 77, into a pair of delivery lines 78 and 80 that are inwardly bent atthe lower ends, and have nozzles 81 and 82 respectively carried thereby,in the vicinity of the upper ends of the elements 30, for heating theelements at a location spaced above the lowermost, or free ends thereof.The elements 30 are connected within bores or recesses 83, by suitablescrews 84, for ease of replacement.

Thus, the application of open flame due to the elimination of gas andoxygen from nozzles 81 and 82, to the elements 30, will heat theelements 30 as aforesaid. It will be noted that elements 30 may also beheated by induction heating (not illustrated), or by other suitablemeans, if desired. In any event, heat is built up and stored in theelement 30, and in order to facilitate this end the element 30 may beconstructed of a high temperature alloy, ceramic, or any other suitablematerial. It will be noted that the flame may continually be applied tothe element 30 during the descent thereof and its retraction, asillustrated in FIGS. 5b and 5c, throughout its engagement with andprojection into the material of the battery posts 20 and 21, if desired,or the heat may be applied to the elements 30 only when the same are intheir uppermost or retracted positions, as desired. In any event, therewill be a transfer of heat from the elements 30 to the upper ends of thebattery posts 20 and 21, that will be constantly replenished by theapplication of heat to the elements 30, by virtue of the application ofopen flame thereto as described above, or by induction heating, or thelike. Furthermore, it will be noted that the heating elements or tips 30may take on various desired physical configurations and sizes, dependingupon the particular application.

Another feature of this invention resides in the use of a plate 90secured to the member 44, by a pair of screws such as 91 and 92, forease of removal of the same, with the plate 90 having a plurality ofopenings, voids, notches or the like, disposed in a uppermost set 93,and a lowermost set 94. The lowermost set 94 is arranged to accommodateplates 53, in accordance with a desired predetermined spacing of element30 relative to each other, as measured horizontally, and relative toposts 20 and 21 of a battery 10 to be welded therebeneath, and alsorelative to the templet 23 mounted on the battery 10 and disposedtherebeneath. Accordingly, placement of the plates 53, in desired onesof the notches 94, will readily accurately position the elements 30, inaccordance with the desired position for welding the posts of a givenbattery, for example. However, the assembly illustrated in FIG. 4 mayreadily accommodate an alternative placement of the elements 30, bymerely removing the plate 90, and inverting the same such that thenotches 93 are disposed downwardly, whereby another placement of theelement 30 relative to each other may readily be effected quickly andeconomically, with minimum set-up time.

With particular reference to FIG. 1, it will be noted that the rod 41 iseither mounted to, or comprises, the piston rod of a piston (not shown),disposed within a piston cylinder 96, mounted on a suitable frame 97.The cylinder 96 is provided with suitable fluid inlets 98 and 100,respectively for providing a downward driving force, for lowering theelements 30, or for retracting the same, depending upon the position ofthe two way valve 101. It will be noted that the fluid supplied throughthe lines 98 and 100 may be any desirable hydraulic, pneumatic fluid orthe like, and that the piston within the cylinder 96 would be driveneither upwardly or downwardly, depending upon the setting of the valve101.

It will be noted that the stroke of the piston contained within thecylinder 96 is controlled to automatically re-set the valve, upon thepiston disposed therein reaching the lower end of a predeterminedstroke, in order that the elements 30 may be retracted prior to strikingthe separator plates or partitions 18. However, in the event ofmisalignment of elements 30 relative to posts 20, 21, or relative to thetemplet 23, or relative to anything else wherein it is desired toprevent a striking of the same by the element 30, or even in the eventthat a battery 10 is raised, for example at one end, due to the presenceof a foreign item between the lower end of the battery and the conveyorrollers 12, such that the battery is "cocked", upon the striking of theelements 30 against any solid member, a sensor of pressure, force or thelike 102, which is particularly responsive to pressure required to lowerthe piston contained within the cylinder 96, and consequently responsiveto resistance to vertical downward movement that the elements 30 maymeet, will be operative to actuate the valve 101, to cause an upwardmovement, or retraction of the assembly 40, and consequently of theelements 30 carried thereby, in order to prevent damage of theapparatus, or to batteries being welded.

Also, with reference to FIG. 1, it will be noted that the rod 41 isprovided with a guide, comprising a plate 103 having a boss 104 disposedabout the rod 41, and carried by the plate 103, and with a guide rod 109being provided, mounted in a suitable bushing 105 carried by a plate106, such that, upon downward movement of the rod 41, the same is guidedagainst undesirable lateral mvoement, due to the presence of the guideplate and rod 103 and 109.

It will thus be seen that the apparatus of this invention is adaptedtoward accomplishing its desired ends, both in broad respects, and inspecific respects, regarding the construction of multiple-cell lead-acidstorage batteries.

It will further be noted that the particular inwardly bent orientationsof the nozzles 81 and 82, present the application of heat to adjacentareas, thereby concentrating the heat on the elements 30 themselves. Itwill also be noted that the element 30 may be adjustably positionedvertically within the blind hole 83, by merely loosening the screw 84and repositioning the element 30. Furthermore, in operation, a properpositioning of the battery can actuate a switch (not shown), that inturn will cause the piston within the cylinder 96 to be actuated, ifdesired.

In view of the above-discussed invention, it has been possible to cutdown the time necessary for completing a weld from thirty seconds tofour seconds. Accordingly, aside from accomplishing improved welds, bothinsofar as their physical appearance and construction is concerned, andinsofar as improving the uniformity and electrical conductivity of thesame is enabled, the overall economics of battery manufacture is greatlyimproved, due to the automation of what has previously been a manualfunction.

An additional advantage over prior techniques of battery post weldmentis also made possible with weldments of this invention. Such resides inthe formation of a homogeneous weldment of adjacent battery posts.Spectrographic analysis of battery posts welded by conventionalapplication of gas and oxygen flame directly to the post results in atendency toward concentration of antimony from the posts at or near thebond of the weld, apparently caused by more severe heat at suchlocations relative to less heat applied to other areas of the weld. Inthermal relay welding as taught by the instant invention, spectrographicanalysis will reveal similar grain structures throughout the weld, inthat the entire post area is heated uniformly and therefore coolsevenly, without causing an antimony precipitation that would result inan antimony concentration. Consequently, the possibility of electrolysisat the antimony interface that forms the junction of dissimilar metalsupon use of the battery in an electrical circuit is avoided by thisinvention, along with any corrosion attendant thereto. Furthermore, thestructural strength of the post weldment is better, because of theabsence of substantial discontinuities that would be formed by suchantimony precipitation.

The foregoing discussion has emphasized the structure of the heatingelements and the apparatus whereby combustible gases are delivered forthe heating thereof. FIGS. 6 through 9 show an alternate illustrativeembodiment wherein the heating elements are integrated with the templetslowered over the battery to form molds for the foregoing heating andmelting process of the terminal posts. Moreover, the embodiment of FIGS.6 through 9 features the heating elements and the molds in an integraladjustable configuration such that batteries having widely disparatestructural characteristics may be processed efficiently withoutrequiring extensive overhaul of the processing mechanism.

In the following description, many elements are identical both instructure and in function to corresponding elements in the foregoingdiscussion. Many of these are numbered similarly to the identicalcorresponding element, but further including a prefixed "7". Thus, forexample, heating elements 730 in FIGS. 6 and 7 correspond identically tothe heating elements 30 in FIGS. 1 through 5d. Unless otherwisespecified, these identical elements shall not be discussed in detail,but shall be assumed to be disclosed completely in the foregoing.

In FIG. 6, a welding mechanism is set up for forming two terminal postsfor batteries. Thus, while the foregoing embodiment included six weldingmechanisms for cell to cell relays in batteries, the embodiment of FIGS.6 through 9 is configured only to form the positive and negativeterminal posts. It is to be understood, however, that any desired numberof heating elements might be included in order to fulfill the desiredwelding requirements for given batteries. Likewise, the embodiment ofFIG. 6 through 9 includes several features which enhance theadaptability and therefore the utility of thermal welding apparatusembodying the principles of the present invention.

In the figures, a pair of heating elements represented generally as 752are affixed to a pair of mounting blocks 612 and 613, which in turn areslidably mounted on a transverse rod 611. This transversely movablemounting permits lateral adjustment of the heating elements 752 toaccomodate batteries having terminal posts located at different points.The transverse rod 611 upon which the blocks 612 and 613 are mounted isterminated at either end by a pair of elements 610. Overlaying both ofthe mounting blocks 612 and 613 and affixed to the elements 609 and 610is a plate 623 which affords control of the adjustability function andwhich shall be described in more detail hereinafter. Also mounted on therod 611 is a fixed block 930 which is in turn connected to the piston830 of a pneumatic or hydraulic cylinder 630. Together, the blocks 609,610, 612, 613 and 930, with the rod 611 and the plate 623, form a"carriage" to which the heating elements 752 are attached, by means ofwhich the heating elements may be moved vertically (such as shown inphantom in FIG. 7) and upon which the respective heating elements may beadjusted transversely.

The terminating blocks 609 and 610 of the carriage upon which theheating elements 752 are mounted are in turn slidably mounted on posts607 and 608, respectively, by means of bearings, not shown. Thus, underthe control of the cylinder 630 and piston 830, the carriage arrangementincluding the heating elements 752 is moved vertically on the posts 607and 608 which are connected at their tops and bottoms, as shown, toelements 616, 617 and 631. Topmost element 631 in turn is mounted onposts 632 and 633, which constitute part of a structural fframe for themechanism.

Also fixedly mounted on the posts 607 and 608 is a manifold head 743which defines conduits 746 and 747 fed by lines 601 and 602 with acombustible gas for flame heating of the heating elements 730. As in theforegoing embodiments, the gases pass through the conduits 746 and 747,through hoses 761 and 762 and into mixing devices 757, and thencedownwardly into the heating means 752. As shown, only two sets of hosesconnect the heating means 752 with the manifold head 743, but it isclear that any number, as desired, might similarly be connected. Alsomounted on he manifold heads 743 is the cylinder 630 whereby themounting carriage for the heating means 752 is movable.

An aspect of the embodiment of FIGS. 6 through 9 which exhibitssubstantial operational efficiency but which was not shown in detail inthe foreging embodiments is the inclusion of a pair of molds 619 and 620which respectively are connected to the mounting blocks 612 and 613 forthe heating means 752. The molds 619 and 620 are slidably mounted on atransverse post 618 through bearings such as 818 and are respectivelymounted on shafts 626 and 627 which are slidably movable through theblocks 612 and 613. It may therefore be seen that the molds 619 and 620are movable as a unit with the upper mounting carriage for the heatingmeans 752 but furthermore are separately movable together by means ofthe sliding of shafts 626 and 627 through the mounting blocks 612 and613.

The molds 619 and 620 are advantageously constructed to provide superioroperational efficiency, which in turn is enhanced by their adaptabilityto process batteries of variable size. This may appreciated byconsideration of the various cutaway views in FIGS. 7 and 8. Theprincipal structural member of the molds 619 includes a hollow channel834 which is fed and exhausted by a pair of lines 634 and 934. Thechannel 834 provides a circulation route for water or other similarcooling fluids to be passed through, and thereby to prevent damage dueto the extreme amounts of heat applied by the heating elements 730 tomake the molten terminal posts. Centrally located on the flat portion ofthe structural housing 619 is a mold member 621 which mates with thestructural housing and which actually forms the voids in which themelting and casting process takes place. The mold members 621 and 622fit into a hole through the structures 619 and 620 and are lockedtherein by means of a slotted key 901 which locks the mold member 621 inplace when situated as shown in FIGS. 7 and 8, but which allows forremoval of member 621 when rotated 180° because the slot 905 then clearsthe outer periphery of the member 621. Lever arm 903 on the key 901limits the rotary motion of the key by cooperating with extensionmembers 902 and 904.

The mold members 621 and 622 are configured as shown to define voids 721having an upper portion which is countersunk. Thus, when the heatingmember 730 is lowered as shown in phantom in FIG. 7 to heat and melt theterminal posts as shown in FIGS. 10a through 10d the level of the moltenmetal rises up into the countersunk portion, but when the heatingelement 730 is removed, the level settles back into the lower portion ofthe void 721 to dry in the standard configuration of a terminal post. Inaccordance with standardized procedures, positive andd negativeterminals of batteries are of different dimension in order to facilitateproper connection with external apparatus. In order to accommodate thewishes of various customers, the mold members 621 and 622 may havedifferent sized voids 721, and may be re-arranged between the molds 619and 620 as desired. Moreover, the molds 621 and 622 shown may be freelyinterchanged with other similar members of different inner-configurationto process battery elements of varying size and configuration, asdesired.

FIG. 9 shows a view of the overlying plate 623 which is affixed in thecarriage assembly to end blocks 609 and 610 by means of cam means 624and 625, and which, when so situated, determines the lateral position ofthe heating means 752. More particularly, the securement means 624 and625 fit through slots 906 and 911 in the plate 623 and screw or boltinto the terminating blocks 609 and 610. The face of the plate definesfirst and second sets of openings 907 and 910, and a plurality of setsof openings such as 908 and 909 extending across the face of the plate.Once the securement members 624 and 625 mount the plate into thecarriage assembly, set screws such as 912 through select ones of the endholes 907 and 910 establish the vertical location of the plate 623.Thereupon, a position is established for the support blocks 612 and 613because they are affixed to the plate 623 by screws 628 and 629 throughappropriate ones of the holes 908 and 909. Thus, use of particular onesof the holes 907 and 910 establish which of the holes 908 and 909(or anyother such sets of holes, as desired) to which the blocks 612 and 613shall be mounted. It is to be understood that by alteration of the holessuch as 908 and 909, any desired position of the heating means 752 onthe shaft 611 may be established. Since the molding apparatus 619 and620 is affixed to the respective blocks by means of posts 626 and 627,similar positioning is established for the molding apparatus 619 and 620on the lower shaft 618. Likewise, in order to accomodate differentnumbers of heating means 752, it would only be required to establishcorrespondingly more sets of holes in the plate 623.

In a preferred mode of operation, the embodiment in FIGS. 6 through 9operates as shown in FIGS. 10a through 10d. In FIGS. 10a through 10d, abushing 920 is mounted around the post hole of the battery casing 732 asis practiced in the art. Thereupon, as the casing is assembled, aterminal post 921 fits into the metallic bushing, to be welded theretoby application of apparatus embodying the principles of the presentinvention. In order to prepare the machinery of FIGS. 6 through 9 foroperation, the plate 623 first is adjusted as desired to locate theheating means and the molding means appropriately over batteries to beprocessed. Once a battery is positioned beneath the FIG. 6 apparatus bymeans of a conveyor or the like, not shown, the cylinder 630 and piston830 are energized to lower the carriage assembly and the moldingapparatus downwardly onto the battery as shown in FIG. 10a. The firstportion to make contact with the battery includes the molding means,which seat as appropriate over the portion to be processed as shown inFIG. 10b. Thereupon, however, the cylinder 630 and piston 830 continuesto exert downward force upon the carriage assembly, as shown in FIG.10b, and a sliding of the carriage over the downward shafts 607, 608,626, and 627 results, such as shown in phantom in FIG. 7. Once theheating means 752 are lowered to the desired position, as shown in FIG.10c, the melting process of bushing 920 and post 921 as describedhereinbefore is conducted, after which the heating means 752 first arewithdrawn and sufficient time is allowed for the molten terminal post toset, as shown in FIG. 10d, and the entire assembly is then withdrawnupwardly.

It may therefore be seen that the principles of the present inventionprovide substantial flexibility, in that variable numbers of heatingmeans 752 may be utilized, but all are freely adjustable in accordancewith the established structure of the plate 623. By utilizing associatedmolding mechanisms, further adaptability is provided, since, first,unitary mold mechanisms are not needed, and, secondly, theinterchangeable mold members 621 and 622 facilitate processes ofdifferent types.

It will also be noted that, while the invention is described andillustrated above, it is principally for use with multiple-terminalapplications, the same may be used for single applications, regardingthe welding of batteries, and with respect to other types of welding.Furthermore, various changes in the details, materials and arrangementof parts, as well as in the use and operation thereof may be effected,all within the spirit and scope of the invention as recited in theappended claims.

What is claimed is:
 1. A method of welding utilizing an apparatus havingat least one heated element for contact-melting engagement with leadmembers to be welded, said element having associated therewith acorresponding templet means defining at least one mold void, said methodfor thermal welding comprising the steps of:a. moving said templet meansto a position wherein it receives said members for welding in said moldvoid; b. applying flame to heat said element to a temperature sufficientto melt said members so that at least a portion of the combustionproducts of said flame flush at least a portion of said members to bewelded with a non-oxidizing atmosphere, thereby substantially preventingthe oxidation of the members being welded; c. moving said heated elementtoward said templet and into engagement with said members to be weldedwithin said mold void; d. melting said members by continued coontactengagement of said element with said members; e. withdrawing saidelement from said mold void after said members are melted; f.maintaining said templet means in position about said members until themelt hardens; g. further withdrawing said element and said templet meansfrom said members.
 2. The invention of claim 1 wherein said maintainingstep involves allowing the molten material to form the final weldedelement substantially in the shape of a portion of said mold void. 3.The invention of claim 1 wherein the step of applying flame heat to saidelement comprises simultaneously applying a plurality of open flames toseparate portions of the outer surface of said element, which flamesfurther act to heat at least a portion of said members to be welded. 4.The invention of claim 1 wherein said open flames are applied to saidelement on opposite sides thereof and are directed toward said melt suchthat at least a portion of the combustion product gases of said flameimpinge upon at least a portion of the melt.
 5. The invention of claim 1wherein in the step of applying flame, the flame is angled toward aportion of said melt to impinge upon at a portion of the melt at leastwhile the element is immersed in the melt.
 6. A method of castingmeltable material comprising the steps ofa. moving a ram relative to thematerial so as to cause the ram to engage the material; b. establishinga reservoir surrounding the ram and engaged with the material to becast; c. heating the ram to a temperature sufficient to convert themeltable material in the path of relative ram movement to the moltenstate; d. moving the heated ram relative to the material and through thereservoir so as to cause the ram to melt the material in its path ofrelative movement to a desired depth in the material with the moltenmaterial thus formed being positively displaced by the ram from the areaof ram penetration into the material and shifted therefrom into thereservoir; e. retracting the ram relative to the material from itsposition of maximum penetration so as to cause the ram to be withdrawnfrom the material; and f. returning the molten material theretoforedisplaced into the reservoir back to the region penetration into themeltable material where such molten material is permitted to cool andsolidify.
 7. A method as set forth in claim 6 further characterized inthat the reservoir is defined by a barrel having a mold at its lower endsurrounding the material to be cast for permitting shaping of the castpart into a configuration defined by the mold cavity.
 8. A method ofbonding n (where n is equal to two or more) components formed ofmeltable material together comprising the steps of:a. positioning the nparts on a work axis; b. moving a ram along the work axis relative tothe n components so as to cause the ram to engage the n components; c.establishing a reservoir surrounding the ram and engaged with the ncomponents to be bonded; d. heating the ram to a temperature sufficientto convert the meltable material in the path of relative ram movement tothe molten state; e. moving the heated ram relative to the n componentsand through the reservoir so as to cause the ram to melt the material inits path of relative movement to a desired depth in the n componentswith the molten material thus formed being positively displaced by theram from the area of ram penetration into the n components and shiftedtherefrom into the reservoir; f. retracting the ram relative to the ncomponents from its position of maximum penetration so as to cause theram to be withdrawn from such components; and g. returning the moltenmaterial theretofore displaced into the reservoir back to the area ofram penetration into the n components where such molten material ispermitted to cool and solidify, thus creating a molecular fusion bondbetween said n component which is coextensive with the depth ofpenetration of the ram into the n components.
 9. The method of bonding ncomponents as set forth in claim 8 further characterized in that saidcomponents include an axially projecting lead battery post and a leadmember concentrically mounted about the post, and wherein the reservoirextends coaxially upward from the member and the ram is moved axiallydownward through the battery post and through the inner peripheralportion of the member surrounding the post so as to melt the upstandingportion of the post and the inner peripheral portion of the member. 10.A method as set forth in claim 9 further characterized in that the leadbattery post projects upwardly through a lead bushing molded in abattery cover and wherein the path of ram movement is coaxial with andthrough the post so that the ram engages and melts the upper ends of thepost and bushing.
 11. An improved method for molecular fusion bonding toform a through-the-wall connection in a lead-acid battery comprising thesteps of:a. positioning the battery with a first lead connectorcomponent disposed on one side of a wall in coaxial relation to anopening formed in said wall; b. positioning a second lead connectorcomponent on the opposite side of the wall and in coaxial relation tothe wall opening; c. positioning a bonding head having a ram and acoaxial barrel adjacent the first connector component with the ramdisposed on the work axis; d. moving the ram and barrel into engagementwith the first connector component while supporting the second connectorcomponent on a stationary work surface; e. heating the ram to atemperature sufficient to convert the lead components in the path of rammovement to the molten state; f. moving the heated ram through thebarrel and axially through the first connector component and into and atleast partially through the second component with the ram positivelydisplacing the molten lead thus formed upwardly into the barrel insurrounding relation with the ram; g. retracting the ram from engagementwith the unmelted portions of the lead components and the molten lead;h. returning the molten lead theretofore displaced into the barrel backto the area of ram penetration into the first and second connectorcomponents where such molten lead is permitted to cool and solidify; andi. retracting the barrel from the first connector component upon coolingand solidification of the molten lead.